|Número de publicación||US5283121 A|
|Tipo de publicación||Concesión|
|Número de solicitud||US 07/789,369|
|Fecha de publicación||1 Feb 1994|
|Fecha de presentación||8 Nov 1991|
|Fecha de prioridad||8 Nov 1991|
|Número de publicación||07789369, 789369, US 5283121 A, US 5283121A, US-A-5283121, US5283121 A, US5283121A|
|Inventores||Barry A. Bordner|
|Cesionario original||Bordner Barry A|
|Exportar cita||BiBTeX, EndNote, RefMan|
|Citas de patentes (14), Citada por (35), Clasificaciones (28), Eventos legales (3)|
|Enlaces externos: USPTO, Cesión de USPTO, Espacenet|
This invention relates to metallic coatings for metal articles prone to corrosion, and, more specifically, to an industrial metallic roll coating with abrasion resistant and release properties that has no through grain porosity.
Metallic roll coatings with abrasion resistant and release properties have in the past been produced using a porous plasma type or wire type flame spray plated based layer and an impregnated Teflon® film top coat. It is believed that the through grain porosity in the plating has not offered completely adequate corrosion resistance in some cases. In fact, older processes such as wire type or plasma type flame spray plating processes are deficient because they do not result in through grain sealed properties, rather they are regarded as porous.
A known process for producing a composite metallic roll having a release surface is disclosed in U.S. Pat. No. 3,942,230 to Nalband. Nalband discloses application of a porous nickel chromium alloy (or other metal) by a flame spray process. Upon the resulting porous metal layer is deposited a fluorocarbon polymer (Teflon®), which is subsequently heated so as to impregnate and cover the porous layer.
In Nalband and other known coating processes, the Teflon layer only provides a corrosion barrier ancillary to the Teflon's principle function of providing a release surface. In recent years, however, operating conditions in industries such as the production of pulp and paper and plastics have generated significantly more demanding requirements in respect to corrosion resistance which are not necessarily within the capabilities of Nalband and other previously known processes.
Accordingly, it is an advantage of the present invention to provide a coating for corrosion prone metal articles including, for example, an industrial roller, comprising an applied textured metal layer with no through grain porosity in order to provide a corrosion and abrasion resistant metal barrier layer over a bare metal article surface such as iron, steel, aluminum or other corrodible metal roller surfaces. Once the textured metal base coating is applied, a thin continuous film of Teflon is bonded over the top of the textured metal to provide a non-sticking or release property to the surface of the article. Further, as the softer Teflon wears, the peaks of the textured surface provide physical protection for the Teflon which lies bonded into the valleys of the textured metal.
It is another advantage of the present invention to provide a composite metallic article, particularly a roll, having highly anti-corrosive properties comprising a body member having a relatively soft and corrodible metal first layer; a middle layer comprising stainless steel, nickel, nickel chromium, or a nickel chromium carbide applied to the first layer by a high-velocity oxy-fuel type metal thermal spray process; and an outer layer comprising a Teflon coating top coated over said middle layer to provide a non-sticking characteristic to the coating.
It is a further advantage of the present invention to provide a method of making a composite metallic article, particularly a roll, having highly anti-corrosive and release properties comprising the steps of providing a body member having a relatively soft and corrodible metal first layer; applying a middle metal layer to the first layer by a high-velocity oxy-fuel type metal thermal spray process; applying an outer layer comprising a Teflon coating over said middle layer to provide a non-sticking characteristic to the coating; and heating said outer layer to a level above the curing temperature of the Teflon so as to set and bond the Teflon to said middle layer.
The above and other features and advantages of the present invention will become apparent from the discussion hereinbelow of a specific, illustrative embodiment thereof presented in conjunction with the accompanying drawings, in which:
FIG. 1 is a broken perspective view of the coating of the present invention shown as applied on a typically shaped roller; and
FIG. 2 is an enlarged cross sectioned detail showing the roller bare metal, the textured base metal coating and the teflon newly applied.
FIG. 3 is an enlarged cross sectioned detail showing the roller bare metal, the textured base metal coating and the teflon after the roll has been used.
In accordance with the present invention, a roll 5, or other metal article being prone to corrosion, comprising a bare metal first surface 10 such as iron, steel, aluminum or other corrodible metal roller surfaces is initially provided With a middle layer comprising a non porous textured metal coating 12 of stainless steel, nickel chromium, or nickel chromium carbide applied over the metal roller surface using a high velocity oxyfuel flame spray process, as produced, for example, by the Metco Perkin Elmer model DJ flame spray gun, to provide an impervious corrosion resistant layer. Before the application of the nonporous textured metal coating 12, it is abrasive grit blasted by known methods in order to increase the volume of its surface area and to provide increased mechanical bonding of the coating metal 12.
A multiple pass high velocity oxy-fuel process is used to obtain a non-porous textured base coating thickness of approximately 0.003" to 0.008" thick in order to insure proper sealing of the roller base metal 10. The non-porous metal coating 12 is applied with a surface finish of 150 to 400 Ra to provide what may be visualized as a miniature peak and valley type of texture.
After the non-porous base metal coating 12 is applied, an outer layer 14 comprising one of the Teflon coatings as manufactured by the DuPont company, Polymer Products Division, is then bonded to the entire surface of the roll 5 in a thin film on the order of 0.001" to 0.006" thick. The exact formula or type of Teflon film used is determined by the final product's requirements for temperature resistance. The Teflon film is applied using a wet pressure spray process in single or multiple layers per the instructions for the grade, required thickness, or type of Teflon used. The Teflon coating 14 is then cured using elevated temperatures ranging from approximately 325° to 640° F. depending on which specific formula is selected for use. The heat used in curing the Teflon can be obtained from a conventional, convection or infrared, gas or electrically fired oven (not shown).
In practice, a roll or other metal article subject to corrosion in view of its relatively soft metal outer layer is coated with a metal layer by a high-velocity oxy-fuel type metal thermal spray process in order to achieve a surface with no through grain porosity. The middle metal layer is preferably applied to a thickness of 0.003" to 0.006" and is then abrasive grit blasting to a surface roughness of between 150 and 400 Ra. By achieving a roughened characteristic, which may be visualized as peaks and valleys, the middle metal layer has an increased surface area for bonding with an outer layer comprising a fluorocarbon polymer (Teflon), which is applied using a wet pressure spray process in single or multiple layers and then cured by heating the composite article to a level above the curing temperature of the Teflon.
The resulting composite metallic article exhibits not only release properties (due to the outer Teflon layer), but is more resistant to severe corrosion, a problem with composite metallic articles produced by previously available processes. Additionally, the above disclosed process which utilizes a noncorroding and textured middle layer provides the Teflon outer layer, which wears down in use, with additional protection from further wear by the highest level (or peak) of the harder middle layer. In other words, even when the outer Teflon layer is virtually completely worn down, Teflon will remain in the valleys of the textured middle layer, thus maintaining at least some release properties for the composite metal article. And, unlike in composite metallic articles produced by previously known processes, even an article whose outer Teflon covering has been worn down through use will continue to resist corrosion.
|Patente citada||Fecha de presentación||Fecha de publicación||Solicitante||Título|
|US2367796 *||8 Jun 1939||23 Ene 1945||Goodrich Co B F||Composite roll|
|US3942230 *||5 Mar 1974||9 Mar 1976||Plasma Coatings, Inc.||Composite metallic roll with release surface and method of making same|
|US4069570 *||2 Dic 1976||24 Ene 1978||Adamovske Strojirny, Narodni Podnik||Cylinders and rollers for printing machines|
|US4391879 *||2 Dic 1981||5 Jul 1983||W. C. Heraeus Gmbh||Gravure printing base cylinder, and method of its manufacture|
|US4522866 *||3 Mar 1982||11 Jun 1985||Olympus Optical Co., Ltd.||Elastomer member with non-tacky surface treating layer and method of manufacturing same|
|US4546527 *||29 Nov 1982||15 Oct 1985||Kubota Ltd.||Composite sleeve for use in rolling rolls for H-section steel and channel steel|
|US4704776 *||25 Abr 1986||10 Nov 1987||Yamauchi Rubber Industry Co., Ltd.||Press roll for paper machines|
|US4856161 *||1 Abr 1988||15 Ago 1989||Valmet Oy||Press roll|
|US4914796 *||12 Dic 1988||10 Abr 1990||Eastman Kodak Company||Process for manufacturing nickel coated shot blasted web conveying roller|
|US4951392 *||6 Ene 1986||28 Ago 1990||Valmet Paper Machinery Inc.||Synthetic press roll for paper machines and method for manufacturing the same|
|US4963404 *||4 May 1987||16 Oct 1990||Stork Screens B.V.||Process for the production of a coated product, thin-walled coated cylinder obtained by using said process, and an ink transfer roller comprising such a cylinder|
|JPS60135558A *||Título no disponible|
|JPS62275511A *||Título no disponible|
|JPS63220912A *||Título no disponible|
|Patente citante||Fecha de presentación||Fecha de publicación||Solicitante||Título|
|US5564196 *||23 Sep 1994||15 Oct 1996||Nomura Techno Research Kabushiki Kaisha||Roll with composite coats|
|US5595601 *||7 Mar 1995||21 Ene 1997||Valmet Corporation||Coating bar for a bar coater|
|US5813962 *||24 Jun 1997||29 Sep 1998||Kawasaki Steel Corporation||Forged roll for rolling a seamless steel pipe|
|US5861692 *||24 Feb 1998||19 Ene 1999||Eastman Kodak Company||Magnetically induced coupling and drive apparatus|
|US5924967 *||28 Jul 1997||20 Jul 1999||Eastman Kodak Company||Wear resistant transport roller|
|US5950310 *||11 Jun 1998||14 Sep 1999||Kawasaki Steel Corporation||Forged roll for rolling a seamless steel pipe and manufacturing method of same|
|US6023051 *||26 Sep 1997||8 Feb 2000||Fellows; Margie Ann||Easily cleanable flavor producing plates for electrically heated barbecue grills and their use in ranges or cooktops|
|US6270849 *||9 Ago 1999||7 Ago 2001||Ford Global Technologies, Inc.||Method of manufacturing a metal and polymeric composite article|
|US6277006 *||21 May 1998||21 Ago 2001||Eastman Kodak Company||Coated media bearing surface for conveying abrasive media and the like|
|US6394944 *||12 May 2000||28 May 2002||American Roller Company||Elastomeric covered roller having a thermally sprayed bonding material|
|US6523262 *||19 Dic 2000||25 Feb 2003||American Roller Company, Llc||Elastomer-covered roller having a thermally sprayed permeable bonding material|
|US6547913 *||7 Sep 2000||15 Abr 2003||Airtrim, Inc.||Apparatus for conveying an adhesively coated scrap lattice web|
|US6616584 *||9 May 2002||9 Sep 2003||American Roller Company, Llc||Elastomeric covered roller having a thermally sprayed bonding material|
|US6666806 *||15 Ene 2003||23 Dic 2003||American Roller Company, Llc||Elastomer-covered roller having a thermally sprayed permeable bonding material|
|US6816340 *||13 Mar 2002||9 Nov 2004||Fuji Photo Film Co., Ltd.||Disk cartridge|
|US6872425||25 Sep 2003||29 Mar 2005||Alcoa Inc.||Coated vehicle wheel and method|
|US7425125 *||27 May 2005||16 Sep 2008||Yutaka Mfg. Co., Ltd||Roller for forming noodles and the like|
|US9322132||12 Nov 2013||26 Abr 2016||Voith Patent Gmbh||Corrosion-resistant roller coating|
|US20020131207 *||13 Mar 2002||19 Sep 2002||Fuji Photo Film Co., Ltd.||Disk cartridge|
|US20030165631 *||31 Mar 2003||4 Sep 2003||Masahiro Sugihara||Coating apparatus and coated-paper manufacturing method|
|US20040142109 *||25 Sep 2003||22 Jul 2004||Kaufold Roger W.||Coated vehicle wheel and method|
|US20040144304 *||14 Ene 2004||29 Jul 2004||Fuji Photo Film Co., Ltd.||Rod for coating machine and method for producing the same|
|US20050247694 *||10 Jun 2005||10 Nov 2005||Abbott Richard C||Resistive heaters and uses thereof|
|US20050266136 *||27 May 2005||1 Dic 2005||Yukata Mfg. Co., Ltd||Roller for forming noodles and the like|
|US20090133618 *||20 Feb 2007||28 May 2009||Fujifilm Corporation||Coating apparatus|
|US20140187959 *||23 Dic 2013||3 Jul 2014||Volcano Corporation||Ultrasound Transducers and Methods of Manufacturing Same|
|CN101394935B||20 Feb 2007||1 Jun 2011||富士胶片株式会社||Coating apparatus|
|CN103534410A *||10 Abr 2012||22 Ene 2014||沃依特专利有限责任公司||Corrosion-resistant roller coating|
|CN103649411A *||4 Jul 2012||19 Mar 2014||沃依特专利有限责任公司||Roll having a wear-resistant non-stick surface|
|EP0894757A1 *||16 Jul 1998||3 Feb 1999||Eastman Kodak Company||Wear resistant transport roller|
|EP1989002A1 *||20 Feb 2007||12 Nov 2008||FUJIFILM Corporation||Coating apparatus|
|EP2573260A1 *||20 Sep 2012||27 Mar 2013||Dirk Richter||Roll and roll coating method|
|WO2000050691A1 *||18 Feb 2000||31 Ago 2000||Carbonell Angel Fernandez||Device for pressing laminated products|
|WO2012156152A1 *||10 Abr 2012||22 Nov 2012||Voith Patent Gmbh||Corrosion-resistant roller coating|
|WO2013004732A1 *||4 Jul 2012||10 Ene 2013||Voith Patent Gmbh||Roll having a wear-resistant non-stick surface|
|Clasificación de EE.UU.||428/381, 428/375, 428/379, 492/58, 428/380, 492/54, 428/389|
|Clasificación internacional||B41N7/00, C23C4/18, F16C13/00, D21F3/08|
|Clasificación cooperativa||Y10T428/294, Y10T428/2942, Y10T428/2944, Y10T428/2933, Y10T428/2958, B41N2207/14, B41N2207/10, C23C4/18, B41N2207/04, F16C13/00, D21F3/08, B41N2207/02, B41N7/00|
|Clasificación europea||B41N7/00, D21F3/08, F16C13/00, C23C4/18|
|9 Sep 1997||REMI||Maintenance fee reminder mailed|
|1 Feb 1998||LAPS||Lapse for failure to pay maintenance fees|
|14 Abr 1998||FP||Expired due to failure to pay maintenance fee|
Effective date: 19980204